operating instructions gb - walsh engineering ewm triton 180 acdc m… · par la présente, nous...

EWM HIGHTEC WELDING GmbH

Dr. Günter - Henle - Straße 8; D-56271 Mündersbach

Phone: +49 (0)2680.181-0; Fax: +49 (0)2680.181-244 Internet: www.ewm.de ; E-mail: [email protected]

Operating instructions GB

Welding machines for TIG and MMA welding

TRITON 180 TRITON 180 AC/DC TRITON 220 DC powerSinus TRITON 220 AC/DC powerSinus

These operating instructions must be read before commissioning. Failure to do so may be dangerous.

Machine may only be operated by personnel familiar with the appropriate safety regulations.

The machines bear the conformity mark and thus comply with the

• EC Low Voltage Guideline (73/23/EEC) • EC EMV Directive (89/336/EEC)

In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments with an increased electrical hazard.

© 2008 Subject to alteration. Item No.: 099-000070-EWM01 Version: 14.02.2008

Originaldokument

liegt jedem Gerät bei!

Original document

is enclosed with each machine!

Document original

est joint à toute machine!

EG - KonformitätserklärungEU - conformity declaration

Déclaration de Conformité de U.E.

Name des Herstellers:Name of manufacturer:Nom du fabricant:

EWM HIGHTEC WELDING GmbH(nachfolgend EWM genannt)(In the following called EWM)(nommé par la suite EWM)

Anschrift des Herstellers:Address of manufacturer:Adresse du fabricant:

Dr.- Günter - Henle - Straße 8D - 56271 Mündersbach – [email protected]

Hiermit erklären wir, daß dasnachstehend bezeichnete Gerät inseiner Konzeption und Bauart sowie inder von uns in Verkehr gebrachtenAusführung den grundlegendenSicherheits-anforderungen der untengenannten EG- Richtlinien entspricht.Im Falle von unbefugtenVeränderungen, unsachgemäßenReparaturen und / oder unerlaubtenUmbauten, die nicht ausdrücklich vonEWM autorisiert sind, verliert dieseErklärung ihre Gültigkeit.

We herewith declare that the machinedescribed below meets the standard safetyregulations of the EU- guidelinesmentionned below in its conception andconstruction, as well as in the design putinto circulation by us. In case ofunauthorized changes, improper repairsand / or unauthorized modifications, whichhave not been expressly allowed by EWM,this declaration will lose its validity.

Par la présente, nous déclarons que laconception et la construction ainsi que lemodèle, mis sur le marché par nous, deláppareil décrit ci - dessouscorrespondent aux directivesfondamentales de sécurité de la U.E.mentionnées ci- dessous. En cas dechangements non autorisés, deréparations inadéquates et / ou demodifications prohibeés, qui nónt pas étéautorisés expressément par EWM, cettedéclaration devient caduque.

Gerätebezeichnung:Description of the machine:Déscription de la machine:

Gerätetyp:Type of machine:Type de machine:

Artikelnummer EWM:Article number:Numéro dárticle

Seriennummer:Serial number:Numéro de série:

Optionen:Options:Options:

keinenoneaucune

Zutreffende EG - Richtlinien:Applicable EU - guidelines:Directives de la U.E. applicables:

EG - Niederspannungsrichtlinie (73/23/EWG)EU - low voltage guidelineDirective de la U.E. pour basses tensionsEG- EMV- Richtlinie (89/336/EWG)EU- EMC guidelineU.E.- EMC directive

Angewandte harmonisierte Normen:Used co-ordinated norms:Normes harmonisées appliquées:

EN 60974 / IEC 60974 / VDE 0544EN 50199 / VDE 0544 Teil 206

Hersteller - Unterschrift:Signature of manufacturer:Signature du fabricant:

Michael Szczesny , Geschäftsführermanaging directorgérant

05.2000

mailto:[email protected]

Dear customer,

Congratulations! You have chosen a quality product from EWM HIGHTEC WELDING GmbH.

EWM machines provide results of the highest perfection thanks to their PREMIUM quality. Therefore we are happy to provide you with a full 3-year warranty according to our operating instructions.

We develop and produce quality! From individual components to the final product, we retain sole responsibility for our machines.

In all their high-tech components, our welding machines embody future-oriented advanced technology at the utmost level of quality. Each of our products is carefully checked; we guarantee that the material and processing of our products is faultless.

These operating instructions contain everything about commissioning the machine, notes regarding safety, maintenance and care, technical data as well as information regarding the warranty. Please heed all these notes to ensure many years of safe operation of the machine.

Thank you for the trust that you have placed in us. We look forward to a long-term partnership with you in the spirit of “ONCE EWM – ALWAYS EWM”.

Yours sincerely,

EWM HIGHTEC WELDING GmbH

Bernd Szczesny

Executive management

Machine and Company Data

Please enter the EWM machine data and your company’s data in the appropriate fields.

CE

EWM HIGHTEC WELDING GMBHD-56271 MÜNDERSBACH

TYP:

ART:

SNR:

PROJ:

GEPRÜFT/CONTROL:

Name of Customer / company

Adress

Post code / Place

Country

Stamp / Signature of EWM-distibutor

Date of purchase

Name of Customer / company

Adress

Post code / Place

Country

Stamp / Signature of EWM-distibutor

Date of purchase

Table of contents Page

Contents/1

Safety instructions ............................................................................................................................. S/1

For your safety ............................................................................................................................ S1 Transport and set-up.................................................................................................................. S/4 Notes on the use of these operating instructions....................................................................... S/4

1 Technical data ...........................................................................................................................1/1

2 Description of the machine......................................................................................................2/1

3 Function specification ..............................................................................................................3/1

3.1 Machine control T2.00 and T2.05 .....................................................................................3/1 3.2 JOB mode .........................................................................................................................3/7

3.2.1 JOB selection .......................................................................................................3/7 3.2.3 Settings in the JOB .............................................................................................3/7

3.3 TIG welding, general.........................................................................................................3/8 3.3.1 Types of ignition: ..................................................................................................3/8 3.3.2 Automatic shut-off ................................................................................................3/8 3.3.3 Digital display .......................................................................................................3/8 3.3.4 TIG welding torch, operating variants ..................................................................3/9

3.3.4.1 Standard TIG torch, 5-pole connection plug ......................................3/9 3.3.4.2 TIG up/down torch, 8-pole connection plug (optional) .......................3/9 3.3.4.3 TIG potentiometer torch, 8-pole connection plug...............................3/9

3.3.5 Tapping mode ......................................................................................................3/9 3.4 TIG function sequences..................................................................................................3/10

3.4.1 Explanation of symbols ......................................................................................3/10 3.4.2 TIG non-latched operation .................................................................................3/11 3.4.3 TIG latched operation ........................................................................................3/12

3.5 TIG pulses.......................................................................................................................3/13 3.5.1 TIG DC pulses (direct current pulses)................................................................3/13 3.5.2 TIG AC pulses (alternating current pulses) (T2.05 only) ...................................3/13 3.5.3 TIG AC special (alternating current pulse special) (T2.05 only) ........................3/13 3.5.4 TIG pulses, function sequences.........................................................................3/14

3.5.4.1 TIG pulses - non-latched operation..................................................3/14 3.5.4.2 TIG pulses - latched operation.........................................................3/14

3.6 MMA welding ..................................................................................................................3/15 3.7 Remote control................................................................................................................3/16 3.8 TIG interface for mechanised welding (remote control connection socket)....................3/17 3.9 General settings..............................................................................................................3/18

3.9.1 Enabling or blocking jobs using a three-digit code ............................................3/19 3.9.2 Setting the torch mode and up/down speed ......................................................3/20

3.9.2.1 Example for using the tables in chapters 3.9.2.2 and 3.9.2.3..........3/20 3.9.2.2 Modes 1-4 for standard torches

(5-pole connection socket; standard)...............................................3/20 3.9.2.3 Modes 1-4 for up/down and potentiometer torch

(8-pole connection socket; optional) ................................................3/21 3.9.2.4 Modes 1-4 for up/down torch with LED display

(12-pole connection socket).............................................................3/22 3.9.2.5 Modes 11-14 without tapping mode.................................................3/22 3.9.2.6 Setting the first jump when increasing or reducing the welding current 3/23

3.9.3 Percentage or absolute values for the ignition or end-crater current.................3/24 3.9.4 Fan test, querying the manufacturer code and setting the mains current limit ..............................................................................................3/25 3.9.5 Changing the three-digit code............................................................................3/25 3.9.6 Exiting the Basic Settings menu ........................................................................3/26

3.10 Restting to the delivery condition....................................................................................3/27 3.11 JP1: Configure welding torch connection .......................................................................3/28

Table of contents Page

Contents/1

4 Quick start – the fastest way to weld ......................................................................................4/1

5 Commissioning .........................................................................................................................5/1

5.1 Area of application ............................................................................................................5/1 5.1.1 Proper usage........................................................................................................5/1

5.2 Setting up the welding machine........................................................................................5/1 5.3 Mains connection..............................................................................................................5/1 5.4 Welding machine cooling system .....................................................................................5/1 5.5 Workpiece lead, general ...................................................................................................5/1 5.6 MMA welding ....................................................................................................................5/3

5.6.1 Electrode holder ...................................................................................................5/3 5.6.2 Workpiece lead ....................................................................................................5/3

5.7 TIG welding.......................................................................................................................5/3 5.7.1 Welding torch, general .........................................................................................5/3 5.7.2 Standard TIG welding torch .................................................................................5/4 5.7.3 TIG up/down and TIG potentiometer welding torch .............................................5/4 5.7.4 TIG up/down welding torch with LED display ......................................................5/4 5.7.5 Shielding gas supply (shielding gas cylinder to the welding machine) ................5/4 5.7.6 Workpiece lead ....................................................................................................5/5

5.8 Cooling unit function specification ....................................................................................5/5 5.8.1 Coolant error ........................................................................................................5/5

6 Maintenance and care...............................................................................................................6/1

7 3-Year Warranty.........................................................................................................................7/1

8 Operating problems, causes and remedies ...........................................................................8/1

9 Spare parts list ..........................................................................................................................9/1

10 Accessories, options ..............................................................................................................10/1

11 Circuit diagrams......................................................................................................................11/1

Safety instructions

S/1

For your safety

Observe accident prevention regulations! Ignoring the following safety procedures can be fatal!

Proper usage This machine has been manufactured according to the latest developments in technology and current regulations and standards. It is to be operated only for the use for which it was designed (see chapter Commissioning/Area of application). Improper usage However, this machine may be a hazard to persons, animals and property if it is • not used as directed • used by unskilled persons who have not been trained • modified or converted improperly

Our operating instructions will provide you with an introduction into the safe use of the machine. Therefore please read them carefully and only start work when you are familiar with them. Any person involved in the operation, maintenance and repair of this machine must read and follow these operating instructions, especially the safety precautions. Where appropriate, this should be confirmed by signature. Furthermore, the • relevant accident prevention regulations, • generally accepted safety regulations, • local regulations, etc. must be observed.

Before undertaking welding tasks, put on prescribed dry protective clothing, e.g. gloves. • Protect eyes and face with protective visor.

Electric shocks can be fatal! • Do not touch any live parts in or on the machine! • The machine may only be connected to correctly earthed sockets. • Only operate with intact connection lead including protective conductor and safety plug. • An improperly repaired plug or damaged mains cable insulation can cause electric shocks. • The machine may only be opened by qualified and authorised specialist staff. • Disconnect from the mains before opening. Switching off is not sufficient. Wait for 2 minutes until the

capacitors have discharged. • Always put down welding torch, stick electrode holder in an insulated condition. • The machine must not be used to defrost pipes!

Even touching low voltages can cause you to get a shock and lead to accidents, so: • Protect yourself from falling before working on platforms or scaffolding. • During welding ensure that you operate earth tongs, torch and workpiece correctly, and not in ways for

which they are not intended. Do not touch live parts with bare skin. • Only replace electrodes when wearing dry gloves. • Never use torches or earth cables with damaged insulation.

Smoke and gases can lead to breathing difficulties and poisoning. • Do not breathe in smoke and gases. • Ensure that there is sufficient fresh air. • Keep solvent vapours away from the arc radiation area. Chlorinated hydrocarbon fumes can be

converted into poisonous phosgene by ultraviolet radiation.

Safety instructions

S/2

Workpiece, flying sparks and droplets are hot! • Keep children and animals well away from the working area. Their behaviour is unpredictable. • Move containers with inflammable or explosive liquids away from the working area. There is a danger

of fire and explosion. • Never heat explosive liquids, dusts or gases by welding or cutting. There is also a danger of

explosions when apparently harmless substances develop high pressures in enclosed containers by heating.

Take care to avoid fire hazards • Any kind of fire hazards must be avoided. Flames can form e.g. when sparks are flying, when parts

are glowing or hot slag is present. • A constant check must be kept on whether fire hazards have arisen in the working area. • Highly inflammable objects, such as matches and cigarette lighters for example, must not be carried in

trouser pockets. • You must ensure that fire extinguishing equipment - appropriate for the welding process - is available

close to the welding work area and that this equipment can be accessed easily. • Containers in which fuels or lubricants have been present must be thoroughly cleaned before welding

begins. It is not sufficient simply for the receptacle to be empty. • After a workpiece has been welded, it must only be touched or brought into contact with inflammable

material when it has cooled down sufficiently. • Loose welding connections can completely destroy protective conductor systems of interior

installations and cause fires. Before beginning welding work, ensure that the earth tongs are properly fixed to the workpiece or welding bench and that there is a direct electrical connection from the workpiece to the power source.

Noise exceeding 70 dBA can cause permanent hearing damage! • Wear suitable earmuffs or plugs. • Ensure that other people who spend time in the working area are not inconvenienced by the noise.

Interference by electrical and electromagnetic fields is possible e.g. from the welding machine or from the high-voltage pulses of the ignition unit. • As laid down in Electromagnetic Compatibility Standard EN 50199, the machines are intended for use

in industrial areas; if they are operated in residential environments, for example, problems may occur in ensuring electromagnetic compatibility.

• The functioning of heart pacemakers can be adversely affected when you are standing near the welding machine.

• It is possible that electronic equipment (e.g. EDP, CNC equipment) in the vicinity of the welding site could malfunction.

• Other mains supply leads, control leads, signal and telecommunications leads above, under and near the welding device may be subject to interference.

Electromagnetic interference must be reduced to a level that no longer constitutes interference. Possible reduction measures: • Welding machines must be serviced regularly. (see Chap. Maintenance and care) • Welding leads should be as short as possible and run closely together on or near to the ground. • Selective shielding of other leads and equipment in the environment can reduce radiation.

Repair and modifications may only carried out by authorised, trained, specialist staff. The warranty becomes null and void in the event of unauthorised interference.

Safety instructions

S/3

Transport and installation

The machines may only be transported and operated in an upright position.

Before carrying away or moving, pull out mains plug and place on the machine.

When setting up the machine, resistance to tilting is only guaranteed up to an angle of 15° (as specified in EN 60974).

Secure the gas cylinder! • Place shielding gas cylinders in the holders provided for them and secure with safety chains. • Take care when handling cylinders; do not throw or heat, guard against them toppling over. • When moving by crane, take off the gas cylinder from the welding machine.

Ambient conditions The welding machine must not be used in a location with risk of explosion For usage, the following conditions must be kept: Temperature range of the ambient air

• During welding: -10°C to +40°C

• During transport and storage -25°C to +55°C. Relative air humidity

• up to 50% at 40°C;

• up to 90% at 20°C.

The ambient air must be free of unusual amounts of dust, acids, corrosive gases or substances, etc., assuming these are not produced by the welding process. Examples of unusual operating conditions:

• unusual corrosive smoke,

• vapour,

• excessive oil vapour,

• unusual vibrations or jolts,

• excessive quantities of dust such as grinding dust etc.,

• severe weather conditions,

• unusual conditions near the coast or on board ship.

When setting up the machine, ensure a free inlet and outlet of air. The machine is tested to protection class IP23, i.e.:

• Protection against penetration of solid foreign bodies ∅ > 12mm,

• Protection against water spray up to an angle of 60° to the vertical.

Safety instructions

S/4

Notes on the use of these operating instructions These operating instructions are arranged into chapters.

To help you find your way around more quickly, in the margins you will occasionally see symbols along with the sub-headings. These symbols refer to particularly important passages of text which are graded as follows depending on their importance:

Please note: Technical features which users must observe.

Warning: Working and operating procedures which must be followed precisely to avoid damaging or destroying the machine.

Caution: Working and operating procedures which must be followed precisely to avoid risk to persons and includes the "Warning" symbol. Instructions and lists detailing step-by-step actions in given situations can be recognised by bullet points, e.g.:

• Insert the welding current lead socket into the relevant socket and lock.

Symbol Description

Press

Do not press

Turn

Switch

1 Technical data

1/1

1.1 TRITON 180 DC; TRITON 180 AC/DC

TRITON 180 DC TRITON 180 AC/DC

Setting range: Welding current / welding voltage

TIG 3 A - 180 A / 10,1 V - 17,2 V 5 A - 180 A / 10,2 V - 17,2 V

MMA 5 A - 140 A / 20,2 V - 25,6 V

Max. welding current at TIG MMA TIG MMA

20ºC ambient temperature: 40%DC 45%DC 50%DC 60%DC 100%DC 40ºC ambient temperature: 35%DC 40%DC 50%DC 60%DC 100%DC

- - -

180 A150 A

-

180 A-

160 A130 A

- -

140 A 130 A 115 A

- -

140 A 130 A 110 A

- - -

180 A 150 A

- -

180 A -

150 A 120 A

- -

140 A 130 A 110 A

- -

140 A 130 A 110 A

Load alternation 10 min (60 % DC ∧ 6 min welding, 4 min break)

Open circuit voltage 88 V 43 V

Mains voltage (tolerances) 1 x 230 V -40 %; +15 % 1 x 240 V -40 %; +10 %

Frequency 50/60 Hz

Mains fuse (slow-blow safety fuse) 1 x 16 A

Mains connection lead 3 x 2.5 mm2 H07RN-F

Max. connected power 5.8 kVA 6 kVA

Recommended generator rating 7.8 kVA 8.1 kVA

cosϕ / efficiency 0,99 / 88 % 1.0 / 89 %

Insulation class / protection classification F / IP 23

Ambient temperature -10 °C to +40 °C

Machine cooling / torch cooling Fan / gas or water

Workpiece lead 35 mm2

Dimensions L x W x H [mm] 480 x 175 x 345 480 x 185 x 390

Weight 12 kg 16,5 kg

Constructed to standards IEC 60974 / EN 60974 / VDE 0544 EN 50199 / VDE 0544 Teil 206

/

1 Technical data

1/2

1.2 TRITON 220 DC; TRITON 220 AC/DC

TRITON 220 DC TRITON 220 AC/DC

Setting range: Welding current / welding voltage

TIG 3 A - 180 A / 10,1 V - 17,2 V 5 A - 180 A / 10,2 V - 17,2 V

MMA 5 A - 140 A / 20,2 V - 25,6 V

Max. welding current at TIG MMA TIG MMA

20ºC ambient temperature: 40%DC 45%DC 50%DC 60%DC 100%DC 40ºC ambient temperature: 35%DC 40%DC 50%DC 60%DC 100%DC

220 A - -

180 A 150 A

220 A

- -

160 A 130 A

- 180 A

- 160 A 140 A

180 A

- -

140 A 110 A

220 A - -

180 A 150 A

220 A

- -

160 A 130 A

- 180 A

- 160 A 140 A

180 A

- -

140 A 110 A

Load alternation 10 min (60 % DC ∧ 6 min welding, 4 min break)

Open circuit voltage 90 V 45 V

Mains voltage (tolerances) 1x230V -40%; +15% 1x240V -40%; +10%

Frequency 50/60 Hz

Mains fuse (slow-blow safety fuse) 1 x 16 A

Mains connection lead 3 x 2.5 mm2 H07RN-F

Max. connected power 5.8 kVA 5.9 kVA

Recommended generator rating 7.8 kVA 8.0 kVA

cosϕ / efficiency 1.0 / 89 %

Insulation class / protection classification F / IP 23

Ambient temperature -10 °C to +40 °C

Machine cooling / torch cooling Fan / gas or water

Workpiece lead 35 mm2

Dimensions L x W x H [mm] 480 x 185 x 390

Weight 16 kg 18 kg

Constructed to standards IEC 60974 / EN 60974 / VDE 0544 EN 50199 / VDE 0544 Teil 206

/

2 Description of the machine

2/1

A1

B1

C1

D1

E1

F1

G1

O1

N1

M1

L1

K1J1

I1

H1

Front view Fig.2 / 1 TRITON 180; 220AC/DC Rear view

A1

B1

C1

D1

E1

F1

G1

I1

K1

O11

M1

L1

H1

Front view Fig.2 / 2 TRITON 180 DC Rear view

2 Description of the machine

2/2

Item Symbol Description

A1 Carrying handle

B1 Operating elements (see chap. 3.1)

C1

G¼ connecting nipple Shielding gas to the welding torch Welding current potential "-"

D1 For the following machine versions:

• 5-pole connection socket Standard TIG torch control lead 8-pole connection socket TIG Up/Down or (optional) Potentiometer torch

• 12-pole connection socket TIG Up/Down torch control lead with (special machine) LED display (current control torch)

E1 +

Welding current socket "+" Workpiece connection, TIG welding, MMA welding connection

F1 - Welding current socket "-" Torch connection, TIG welding, MMA welding connection

G1 Cooling air inlet openings

H1 Cooling air outlet openings

I1 Mains cable with connector plug

J1

5-pole connection socket Cooling unit voltage supply

K1

G¼ connecting nipple Shielding gas connection on the pressure reducer

L1

Main switch Machine On/Off

M1 19-pole connection socket Remote control connection

N1 8-pole connection socket Cooling unit control lead

O1

HF

HF

Changeover switch Types of ignition: HF HF ignition HF Liftarc (contact ignition)

3 Function specification

3/1

3.1 Machine controls T2.00 and T2.05

AMP%AMP%

AMP

AMP

secsec

sec

secAMPAMP

sec

sec

sec

AMP

T2.00

PULS

AMP

VOLT

JOB

JOB

S

A1W1 B1 C1 D1

N1

O1

P1

Q1

R1

E1

I1

J1

K1

L1M1

H1 G1 Fig. 3/1: T2.00 (TRITON 180; 220 DC)

JOB 05050

7575

100100

125125150150

175175

200200HzHz1,01,0

1,61,6

2,42,4

3,23,2

4>4>

00+10+10

+20+20

+30+30 -30-30

-20-20

-10-10

%%

mmmm

AMP%AMP%

AMP

AMPAMP

secsec

sec

secsecAMPAMP

JOBsecsec

secsec

sec

AMP

T2.05

SS

PulsAC/DC

Puls

Hz%

mmmm

DC +DC +

DC -DC -

ACAC

ACAC

ACAC

AMP

VOLT

JOB

A1

S1.1

S1.2

S1.3

W1

V1

H1

I1

J1

K1

L1

M1 N1

O1

P1

Q1

R1

G1

U1 T1

F1

B1 C1 D1 E1

Fig. 3/2: T2.05 (TRITON 180; 220 AC/DC)


3/2

Item Symbol Description A1

Three-figure display (on when the machine is ready to operate) Depending on the setting on the key button (B1), displays the welding current, welding voltage or JOB number. Display of error messages (see chap. 7)

Display of the welding parameter values

for the TIG process (G1): Gas pre-flow time (I1), ignition current (J1), up-slope time (K1), main current (L1), pulse time (M1), secondary current (O1), pulse pause time (N1), down-slope time (P1), end-crater current (Q1), gas post-flow time (R1), additionally for T2.05: Frequency (S1.1), balance (S1.2) and tungsten electrode diameter (S1.3).

for the MMA process (G1): Hotstart current (J1), Hotstart time (K1), main current (L1),

Select the relevant signal lights using key buttons from top to bottom.

Item Symbol Description B1 AMP

VOLT

JOB

Display switching: AMP Welding current display VOLT Welding voltage display JOB Job number display

C1

Welding method:

MMA welding

TIG welding

D1

Operating modes (TIG):

non-latched

latched

This switchover also affects the parameters up-slope time (K1) and down-slope time (P1), which can be set separately for non-latched and latched modes.

E1

PulsAC/DC

Puls

Standard TIG welding / TIG pulses and TIG AC/DC pulses:

Standard TIG welding Puls

TIG pulses

Additionally for T2.05:

PulsAC/DC

TIG AC/DC pulse special (only possible with AC)


3/3

Item Symbol Description F1 DC +DC +

DC -DC -

ACAC

ACAC

ACAC

Current type (T2.05):

MMA

DC +DC + Direct current welding with positive polarity on electrode holder in relation to the workpiece (pole reversing switch).

TIG and MMA

DC -DC - Direct current welding with negative polarity on the torch (or electrode holder) in relation to the workpiece.

TIG

ACAC A.C. current welding with rectangular current output wave form. Maximum power loading and safe welding.

ACAC A.C. current welding with trapezoidal current output wave form. The allrounder for most applications.

ACAC A.C. current welding with sinusoidal current output wave form. Low noise level.

G1

Key buttons for selecting the welding parameter signal lights

for the TIG process:

Gas pre-flow time (I1), ignition current (J1), up-slope time (K1), main current (L1), pulse time (M1), secondary current (O1), pulse pause time (N1), down-slope time (P1), end-crater current (Q1), gas post-flow time (R1),

Additionally for T2.05: Tungsten electrode diameter (S1.3), balance (S1.2) and frequency (S1.1).

for the MMA process:

Hotstart current (J1), Hotstart time (K1), main current (L1)

H1

AMPAMPJOB

Rotary transducer for setting all parameters for the TIG and MMA processes (G1).


3/4

During the welding process, LEDs I1 to R1 show the progress of the welding sequence, e.g. during the gas pre-flow stage, LED I1 will be on.

Welding parameter signal lights can be selected via key buttons

Item Symbol Description I1 secsec

Gas pre-flow time (TIG): 0.1s -5.0s; 0.1s increments.

J1 AMP Ignition current (TIG): There are no pulses during the ignition current phase. as a percentage of the main current (factory setting) 0 - 100% of main current; 1% increments. absolute values (chap. 3.10.3: changeover from percentage to absolute) I min* - I max; 1A increments. Hotstart current (MMA): as a percentage of the main current (factory setting) 0 -150% of main current; 1% increments. absolute values (chap. 3.10.3: changeover from percentage to absolute) I min - I max; 1A increments.

K1 secsec Up-slope time (TIG): 0.1s -20.0s; 0.1s increments. The Up-Slope time can be set separately for non-latched and latched. Hotstart time (MMA): 0.1s - 5.0s; 0.1s increments

L1 AMP Main current (TIG): I min* - I max; 1A increments. Main current (MMA): I min - I max; 1A increments

M1 secsec Pulse time (TIG): 0.01s - 10.0s; 0.1s increments. Can be selected if TIG pulses is set. The pulse time applies to the main current phase (AMP) for pulses. Additionally for T2.05: Can be selected if TIG AC/DC pulses is set. The pulse time applies to the AC phase for AC/DC pulses.

O1 AMP Secondary current (TIG): 0 - 100% of the main current; 1% increments. Additionally for T2.05: The secondary current is also active during the DC phase of the AC/DC pulses.

N1 secsec Pulse pause time (TIG): 0.01s – 10.0s; 0.01s increments. Can be selected if TIG pulses has been set. The pulse pause time applies to the secondary current phase for pulses. Additionally for T2.05: Can be selected if TIG AC/DC pulses is set. The pulse pause time applies to the DC phase for AC/DC pulses special.

P1 secsec Down-slope time (TIG): 0.1s -20.0s; 0.1s increments. The down-slope time can be set separately for non-latched and latched.

Q1 AMP End-crater current (TIG): as a percentage of the main current (factory setting) 0 - 100% of main current; 1% increments. absolute values (chap. 3.10.3: changeover from percentage to absolute) I min* - I max; 1A increments.

R1 secsec Gas post-flow time (TIG): 0.1s -20.0s; 0.1s increments.

* Note for TRITON 220 AC/DC: With an electrode diameter greater than 1mm, the minimum current is raised by I min.


3/5

T2.05 only:

Items S1.1, S1.2 and S1.3 are active in all JOBs (except in JOB 0) (See chap. 3.2). The rotary dials T1, U1 and V1 are deactivated (JOB 1 - 7).

Item Symbol Description

AC frequency (AC): S1.1 Hz 50Hz - 200Hz; 1Hz increments. Constriction and stabilisation of the arc. At a higher frequency, the cleaning effect is increased. Particularly thin panels (welding with a low current), anodised sheet aluminium or highly contaminated articles for welding can be welded and cleaned perfectly at a higher frequency.

AC balance (AC): S1.2 %

-30% - +30%;1% increments. Optimisation of cleaning effect and fusion penetration characteristics. An increase in the positive half-wave means: - greater cleaning effect - higher temperature of the tungsten

electrode - greater ball formation on the tungsten

electrode - broader weld seam, little fusion penetration An increase in the negative half-wave means: - narrower weld seam, deeper fusion

penetration - smaller cleaning effect - lower temperature of the tungsten electrode- smaller ball formation on the tungsten

electrode

Tungsten electrode diameter (TIG): S1.3 mmmm

1.0mm -4.0mm; 0.1mm increments. The best ignition and stabilisation of the arc as well as (DC, AC) optimum ball formation in the tungsten electrode depend on the electrode diameter being used (AC). With an electrode diameter greater than 1.6 mm, the minimum current is raised by I min (DC, AC).

mmmm


3/6

T2.05 only:

Items T1, U1 and V1 are only active in JOB 0 (see chap. 3.2). Signal lights S1.3 , S1.2 and S1.1 are deactivated.

Item Symbol Description T1

1,01,0

1,61,6

2,42,4

3,23,2

4>4>

mmmm

Tungsten electrode diameter (TIG):

1.0mm -4.0mm. (For more detailed description, see item S1.3)

U1 00+10+10

+20+20

+30+30 -30-30

-20-20

-10-10

%%

AC balance (TIG):

-30% - +30%. (For more detailed description, see item S1.2)

V1

5050

7575

100100

125125150150

175175

200200HzHz

AC frequency (TIG):

50Hz -200Hz. The maximum adjustable frequency is influenced by the main current set. (For more detailed description, see item S1.1)

Item Symbol Description W1 SS

T2.05 only (TIG and MMA):

Indicates that welding is possible in environments with increased electrical risks (e.g. in boilers).

If the LED is off, the service department must be informed.

Excess temperature (TIG and MMA):

Thermal monitors in the power unit trigger at excess temperature and the excess temperature control lamp comes on. After cooling, welding can proceed without any further measures.

Water deficiency (TIG):

Indicates a water deficiency in welding machines cooled by liquids.

Collective interference (TIG and MMA):

If the collective interference signal light is on, the power unit is automatically switched off. Because some interference is short-term and one-off (e.g. mains voltage surges), the signal light will go out again and the welding machine is ready for welding. If the collective interference signal light continues to be on after an appropriate waiting time, see the chapter on troubleshooting.


3/7

3.2 JOB mode

For frequently used welding tasks, 8 JOBs (JOB 0 - JOB 7) can be selected, changed and saved. All settings for the user interface T2.00 or T2.05 are stored in each JOB. On delivery and after each re-initialisation (see chap. 3.10) the control will be on JOB 0. For the T2.05 the potentiometer electrode diameter (T1), alternating current balance (U1) and alternating current frequency (V1) are active and the functions S1.1, S1.2 and S1.3 are inactive in this JOB. In JOBs 1-7, the functions S1.1, S1.2 and S1.3 are active and the rotary transducers T1, U1 and V1 are inactive.

• Each time the machine is switched on, the display (A1) will display the current JOB number for two seconds. The LED (B1) JOB is on, all other LEDs are deactivated.

• It is only possible to switch over to a JOB if the machine is in STOP mode (Stop mode: Machine switched on and ready for operation; before and after welding).

• For resetting JOBs to the condition on delivery and blocking JOBs, see chaps. 3.10 and 3.9.1.

3.2.1 JOB selection Control element Action Result Display

AMP

VOLT

JOB

X x

Select JOB mode JOB number

AMPAMPJOB

Change the JOB number JOB number

AMP

VOLT

JOB

1 x

If the display switchover (B1) is pressed or if there is no keyboard input for 5 seconds, the new JOB will be active.

JOB number

3.2.3 Settings in the JOB Control element Action Result Display

AMP

VOLT

JOB

X x

Select JOB mode JOB number

AMPAMPJOB

Required JOB number JOB number

X x

Select parameters for the TIG or MMA process. If the next parameter is selected or if there is no keyboard input for 5 seconds, the parameter value will be saved

Parameter values

AMPAMPJOB

Setting the parameter values Parameter values

AMP

VOLT

JOB

X x

If the display switchover (B1) is pressed or if there is no keyboard input for 5 seconds, the JOB will be saved.

JOB number

The up-slope and down-slope times can be set separately for non-latched and latched.


3/8

3.3 TIG welding, general 3.3.1 Types of ignition:

HF ignition

The arc is started without contact by high-voltage ignition pulses.

Liftarc

The arc is ignited on contact with the workpiece:

a) The torch gas nozzle must be placed with its rim on the ignition point to give a gap of approx. 2-3 mm between the electrode tip and the workpiece.

b) Carefully touch the workpiece with the tungsten electrode tip. Press torch trigger in accordance with the operating mode selected.

c) The arc ignites when the torch is lifted off and swivelled to its normal position.

Fig. 3/3: Liftarc

3.3.2 Automatic shut-off

If ignition of the arc does not occur after starting or if the arc is interrupted when the torch is moved away, an automatic cut-out occurs after 3 sec. HF, gas and the open circuit voltage (power unit) are switched off.

3.3.3 Digital display The digital display (A1) indicates the following:

• Welding current

• Welding voltage

• Job number

• Error messages.

The welding current, welding voltage or job number is displayed using the key button (B1).

It also displays all adjustable values in the TIG process using the key button (G1) for selection and the rotary transducer (H1) to set the individual points in the TIG process.


3/9

3.3.4 TIG welding torch, operating variants The welding process can be controlled with various torch designs (TT=torch trigger):

3.3.4.1 Standard TIG torch, 5-pole connection plug (factory setting)

The welding machine is prepared for these torch types as standard.

Symbol Description Functions Operation with Welding current On/Off TT 1

Standard TIG torch Design: 1 trigger Secondary current TT 1 in tapping mode

Welding current On/Off TT 1 Secondary current TT 2

Standard TIG torch Design: 2 triggers

Secondary current TT 1 in tapping mode

Welding current On/Off TT 1 (rocker forwards) Secondary current TT 2 (rocker back)

Standard TIG torch Design: 2 triggers (MG rocker)

Secondary current TT 1 (rocker forwards) in tapping mode

Special functions with standard TIG torches such as e.g. Up/Down operation (see Chapter 3.9.2)

3.3.4.2 TIG up/down torch, 8-pole connection plug (optional)

The welding machine is prepared for this torch type as standard.

Symbol Description Functions Operation with Welding current On/Off TT Secondary current TT in tapping mode

TIG up/down torch Design: 1 trigger + 2 triggers (rocker) Increase / reduce

welding current Rocker forwards / rocker back

The last welding current set is stored in the memory and is available after switching on again.

3.3.4.3 TIG potentiometer torch, 8-pole connection plug

For machines with 8-pole connection sockets (optional), it is not possible to differentiate between TIG up/down torches and potentiometer torches via the torch detection system

Before commissioning, the welding machine must be converted for the TIG potentiometer torch. (see chapter 3.11)

The TIG potentiometer torch can only be used in mode 3.

Symbol Description Functions Operation with Welding current On/Off TT Secondary current TT in tapping mode

TIG potentiometer torch Design: 1 trigger + 1 wheel (potentiometer) Increase / reduce

welding current Turn potentiometer backwards / forwards

3.3.5 Tapping operating mode The tapping mode was included particularly for the secondary current (AMP%) by the use of a trigger on the welding torch.

Torch with one trigger:

• by tapping (brief pressing and releasing) torch trigger 1 (Repeated tapping switches back to the main current).

Torch with two triggers:

There are two ways of switching to the secondary current:

• by tapping (see torch with one trigger)

• by pressing down and holding torch trigger 2.


3/10

3.4 TIG function sequences All the parameters for the TIG process can be controlled using the key button (G1) to select the parameters and the rotary transducer (H1) for setting them:

• Main current AMP,

• Secondary current AMP%,

• Gas pre-flow time,

• Ignition current,

• Up-slope time,

• Pulse current time,

• Pause current time,

• Down-slope time,

• End-crater current,

• Gas post-flow time,

• Electrode diameter,

• Balance,

• Frequency.

3.4.1 Explanation of symbols Symbol Meaning

Press torch trigger 1

Release torch trigger 1

AMP Main current (minimum to maximum current)

AMP% Secondary current (0% to 100% of AMP)

Istart Ignition current

Iend End-crater current

tUp Up-slope time

tDown Down-slope time

TIG welding process

MMA welding process

Standard TIG welding

TIG pulses On

Non-latched mode

Latched mode

HF

HF ignition switched on

HF

Liftarc

Gas pre-flows

Gas post-flows


3/11

3.4.2 TIG non-latched operation • Adjust the appropriate key buttons or changeover switches to the following settings:

HF

When the foot-operated remote control RTF is connected, the machine switches automatically to non-latched operation. The up- and down-slopes are switched off.

I

Istart

AMP

tUp

1. 2.

tDown

Iend

t

Fig. 3/4: Function sequence of TIG non-latched operation

1st step:

• Press and hold torch trigger 1.

• The gas pre-flow time passes.

• HF ignition pulses jump from the electrode to the workpiece, the arc ignites.

• The welding current flows and immediately assumes the value set for the ignition current Istart.

• HF is switched off.

• The welding current increases in the adjusted up-slope time to the main current AMP.

2nd step:

• Release torch trigger 1.

• The main current falls in the adjusted down-slope time to the end-crater current Iend (minimum current).

• The main current reaches the end-crater current Iend, the arc extinguishes.

• The gas post-flow time set passes.

If the 1st torch trigger is pressed during the down-slope time, the welding current returns to the main current AMP set.


3/12

3.4.3 TIG latched operation • Adjust the appropriate key buttons or changeover switches to the following settings:

HF


I

Istart

AMP

Iend

tUp tDown

t

AMP%

1. 2. 3. 4.

Fig. 3/5: TIG latched function sequence

Step 1

• Press torch trigger 1, the gas pre-flow time passes.

• HF ignition pulses jump from the electrode to the workpiece, the arc ignites.

• Welding current flows and immediately assumes the ignition current value set (search arc at minimum setting). HF is switched off.

Step 2

• Release torch trigger 1.

• The welding current increases in the set up-slope time to the main current AMP. (Secondary current AMP% see chap. 3.1)

Switching from the main current AMP to the secondary current AMP%:

• Press torch trigger 2 or • Tap torch trigger 1 (tapping mode see also chap. 3.3.5)

Step 3

• Press torch trigger 1.

• The main current falls in the set down-slope time to the end-crater current Iend (minimum current).

4th step

• Release torch trigger 1, the arc extinguishes.

• The gas post-flow time set begins.

Immediate termination of the welding procedure without down-slope and end-crater current:

• Briefly press the 1st torch trigger (3rd and 4th step). The current falls to zero and the gas post-flow time begins.


3/13

3.5 TIG pulses

The machines have an integrated pulse device. The following options are available:

T2.00: • TIG DC pulses T2.05: • TIG DC pulses • TIG AC pulses • TIG AC pulses - special

The TIG DC and TIG AC pulses – with the exception of AC pulses special – can also be realised with the pulse remote controls RTP1 and RTP2.

3.5.1 TIG DC pulses (direct current pulses) AMP = pulse current

AMP% = pulse pause current tpuls = pulse time tpause = pulse pause time (see fig. 3/6)

AMP

AMP%

tpausetpuls

AMP

t

Fig. 3/6

3.5.2 TIG AC pulses (alternating current pulses) (T2.05 only)

AMP = pulse current AMP% = pulse pause current tpuls = pulse time tpause = pulse pause time (see fig. 3/7)

tpause tpuls

t

AMP

AMP

AMP%

Fig. 3/7

3.5.3 TIG AC special (alternating current pulse special) (T2.05 only)

AMP = pulse current alternating current phase AMP% = pulse pause current direct current phase tpuls = pulse time; time of the alternating current phase tpause = pulse pause time; time of the direct current phase (see fig. 3/8) Application: e.g. for welding thick panels to thin panels.

AMP

AMP%

tpause tpuls

AMP

t

Fig. 3/8


3/14

3.5.4 TIG pulses, function sequences

The function sequences of TIG pulses are principally the same as for standard TIG welding. As soon as the arc has ignited, the current switches backwards and forwards between the pulse current and pause current at particular times.


See the explanation of symbols in chap. 3.4.1.

3.5.4.1 TIG pulses - non-latched operation

• Adjust the appropriate key buttons or changeover switches to the following settings:

HF

AMP%

I

Istart

AMP

Iend

tUp tDownt

1. 2.

Fig. 3/9: TIG pulses non-latched function sequence

Explanation as in chap. 3.4.2

3.5.4.2 TIG pulses - latched operation

• Adjust the appropriate key buttons or changeover switches to the following settings:

HF

I

Istart

AMP

Iend

tUp tDown

t

AMP%

1. 2. 3. 4.

Fig. 3/10: TIG latched function sequence

Explanation as in chap. 3.4.3


3/15

3.6 MMA welding • Adjust the appropriate changeover switches to the following settings:

This machine has the following features in electrode operation:

Arcforcing

Shortly before the electrode threatens to stick, the arcforcing device sets an increased current designed to prevent the electrode sticking.

Hotstart

The hotstart device improves the ignition of the stick electrodes using an increased ignition current.

Antistick

If the stick electrode sticks despite the arcforcing device, the machine automatically switches over to the minimum current within about 1 second to prevent the electrode overheating. If the antistick device has been triggered, check the main current setting and if necessary correct it.


3/16

3.7 Remote control

• Only the remote controls described in these operating instructions should be connected.

• Only plug and lock the remote control unit into the remote control connection socket and only when the machine is switched off.

• For remote controls without cables, a remote control connection cable should be used.• See the operating instructions on the remote control for more detailed information.

Foot-operated remote control RTF 1 Manual remote control RT1

Functions:

• Welding current "ON/OFF" (switches on after the pedal has been pressed).

• Infinitely adjustable welding current (in %) depending on the preselected main current or I1 of the welding machine.

Functions:

• Infinitely adjustable welding current (in %) depending on the welding current I1 preselected on the welding machine.

When the foot-operated remote control RTF 1 is connected, the machine switches automatically to non latched operation. The up- and down-slopes are switched off.

RTP 1 manual remote control RTP 2 manual remote control

Functions: • TIG / MMA • Pulse / spot / normal • The percentage settings

of the main and secondary current depending on the preselected welding current I1 of the welding machine.

• Pulse, spot and break times are infinitely adjustable.

• TIG AC pulses special is not possible.

Functions: • TIG / MMA • Pulse / spot / normal • The percentage settings of

the main and secondary current depending on the preselected welding current I1 of the welding machine.

• Frequency and spot times infinitely adjustable.

• Coarse adjustment of the cycle frequency.

• Pulse/pause ratio (balance) adjustable from 10% to 90%.

• TIG AC pulses special is not possible

• For remote controls RTP 1 and RTP 2, adjust the following settings on the appropriate changeover switch:


3/17

3.8 TIG interface for mechanised welding (remote control connection socket) The welding current sources feature a very high standard of safety. This safety standard is also retained when peripheral equipment is connected for automatic welding if this peripheral equipment fulfils the same criteria, particularly with regard to their isolation from the mains supply.

This is ensured by the use of transformers according to VDE 0551. The welding machines are equipped for automated operation as standard.

For automated applications, control inputs and a galvanically isolated relay contact are available at the remote control connection socket.

Interface for mechanised welding

19-pole connector socket:

• Pin A Output: Connection for cable screen.

• Pin B/L Output: Current relay contact (I>0) to the user (galvanically isolated) maximum load +/- 15 V / 100 mA.

• Pin F Output: Potentiometer reference voltage 10 V, max. 10 mA.

• Pin K Output: Power supply +15V, max. 75mA.

• Pin V Output: Power supply -15V, max. 25mA.

• Pin C Input: Nominal value for main current, 0-10V (0V = Imin, 10V = Imax)

• Pin D Input: Nominal value for secondary current, 0-10V (0V = Imin, 10V = Imax).

• Pin J/U Output: 0V

• Pin R Input: Start / stop.

• Pin H Input: Switching between main and secondary current.

• Pin S Input: Switching between MMA and TIG operation.

• Pin M/N/P Input: Nominal value identification.

• Pin G Output: Inominal 0-10V Schirm für KabelSchirm für Kabel

10V/max.10mA

A

B

L

F

C

D

E

T

S

V

K

U

J

R

H

M

N

P

G

I > 0I > 0

frei

frei

0V

+15V/75mA

-15V/25mA

Start/Stop

Wig/Elek.

Pulser I /IPulser I /IH L

FR-Typ1

FR-Typ2

FR-Typ3

ISOLL

Kennung SollwertvorgabeKennung Sollwertvorgabe

Start Stop WigElek

Ab-

senk-

strom

IL HI

strom

Haupt-

PE

10k10k

Hauptstrom 0-10VHauptstrom 0-10V

externer Sollwertexterner Sollwert

Kennung

Sollwertvorgabe

Kennung

Sollwertvorgabe

externer Sollwertexterner Sollwert

Absenkstrom 0-10VAbsenkstrom 0-10V

= externer Sollwert

für Hauptstrom aktiv

= externer Sollwert

für Hauptstrom aktiv

= externer Sollwert

für Haupt- und

Absenkstrom aktiv

= externer Sollwert

für Haupt- und

Absenkstrom aktiv

Fig. 3/8: Interface for mechanised welding, 19-pole


3/18

3.9 General settings The following settings are possible:

• Enabling or blocking inputs using a three-digit code

• Determine the torch mode and up/down speed

• Ignition and end-crater current can be switched from percentages to absolute values; adjustable alternating current waveforms (rectangular, trapezoidal and sinusoidal)

• Fan test, querying the software version and setting the mains current limit

• Changing the three-digit code

• Exiting the Basic Settings menu

Procedure:

Control element Action Result Display

Press the key button (B1) when switching on the machine.

After pressing the key button (B1) when the machine is switched on, the rotary transducer (H1) can be used to switch between multiple menu options. (see Overview and chaps. 3.9.1 - 3.9.6). The menu sub-options are selected using the key button (G1) and are set using the rotary transducer (H1). The procedure for exiting the menu options is described in chap. 3.9.6.

Overview:

Menu options Sub-options

Enter code

Enable

Enabling or blocking the setting options using a three-digit code (see chap. 3.9.1)

Block

Torch mode

Setting the torch mode and up/down speed (see chap. 3.9.2) Up/down speed

Percentage

Absolute

Positive ignition pulse switched off

Percentage or absolute values of ignition or end-crater current; select positive ignition pulse (see chap. 3.9.3)

Positive ignition pulse switched on

Percentage

Percentage or absolute values for the ignition or end-crater current (see chap. 3.9.3) Absolute

Fan off

Fan on

Query manufacturer code

Mains current 16A

Fan test, querying the manufacturer code, setting the mains current limit (see chap 3.9.4)

Mains current 10A

Current code

Changing the three-digit code (see chap. 3.9.5)

New code

Exiting the Basic Settings menu (see chap. 3.9.6)


3/19

3.9.1 Enabling or blocking the jobs using a three-digit code

Please see chap. 3.9 for information on accessing and setting the menu options

After blocking, only the main current can be set. With the exception of the main current, all setting options described in chap. 3.1 are blocked.


AMPAMPJOB

Turn the rotary transducer (H1) until the display shown to the right appears.

First digit of the code. Digit will flash.

AMPAMPJOB

Set the first digit.

Second digit of the code. Digit will flash.

AMPAMPJOB

Set the second digit.

Third digit of the code. Digit will flash.

AMPAMPJOB

Set the third digit.

3s

or

AMPAMPJOB

Set Block (on) or Enable (off)

or


3/20

3.9.2 Setting the torch mode and up/down speed



AMPAMPJOB


Torch mode

AMPAMPJOB

Set torch mode

Up/down speed

AMPAMPJOB

Set up/down speed

3.9.2.1 Example for using the tables in chapters 3.9.2.2 and 3.9.2.3

Requirement:

• Up/down function with standard TIG torch (2 triggers, 5-pole connection socket)

• Select the function

• Select the relevant mode

3.9.2.2 Modes 1-4 for standard torches (5-pole connection socket; standard)

Standard torch with one torch trigger (TT)

Standard torch with two torch triggers: TT1 = left TT2 = right

Standard torch with MIG rocker

Symbol Functions Mode 1 (factory set.)

Mode 2 Mode 3 Mode 4

Welding current On/Off

TT 1 Not applicable TT 1 TT 1

Secondary

current in tapping mode


Welding current On/Off

TT1 Not applicable TT 1 TT 1

Secondary current

TT 2 Not applicable -------------------- TT 2

Secondary current in tapping

mode


Up function ------------------- Not applicable Tap + press TT 2

--------------------

Down function ------------------- Not applicable TT 2 --------------------


3/21

Symbol Functions Mode 1

(factory setting)


Welding current On / Off

Rocker forward

Rocker in centre

Rocker forward Rocker forward

Secondary current

Rocker back -------------------- -------------------- Rocker back

Secondary current in tapping

mode

Rocker forward

Rocker in centre

Rocker forward Rocker forward

Up function ------------------- Rocker forward Tap + press rocker back

--------------------

Down function ------------------- Rocker back Rocker back --------------------

3.9.2.3 Modes 1-4 for up/down and potentiometer torch (8-pole connection socket; optional)

Up/Down torch with one torch trigger (TT)

Up/Down torch with two torch triggers:TT1 = left TT2 = right

Potentiometer torch with one torch trigger (TT)

Potentiometer torch with two torch triggers:TT1 = left TT2 = right

Symbol

Functions Mode 1 (factory setting)


Welding current On / Off TT TT TT TT

Secondary current in tapping mode

TT TT TT TT

Increase / reduce welding current

Rocker forwards /

rocker back

------------------- -------------- -----------

Select JOBs up/down ------------------- Rocker forwards /

rocker back

-------------- -----------

Increase / reduce welding current increment =

adjustable (see 3.9.2.6)

------------------- ------------------- -------------- Rocker forwards /

rocker back

Welding current On / Off TT 1 TT 1 TT 1 TT 1

Secondary current TT 2 TT 2 TT 2 TT 2


TT 1 TT 1 TT 1 TT 1


Rocker forwards /

rocker back

------------------- -------------- -----------

JOB mode selection only possible in Stop mode*

------------------- ------------------- -------------- Tap TT2

Select JOBs up/down ------------------- Rocker forwards /

rocker back

-------------- Rocker forwards /

rocker back

Gas test (gas flows 30s) only possible in Stop mode*

------------------- ------------------- -------------- Press TT2 for 3 secs.

Increase / reduce welding current increment =

adjustable (see 3.9.2.6)

------------------- ------------------- -------------- Rocker forwards /

rocker back


3/22

Symb

ol Functions Mode 1

(factory setting)


Welding current On/Off TT TT TT TT Secondary current in

tapping mode TT TT TT TT

Increase / reduce welding

current ------------------- ------------------- Turn

potentiometer

backwards / forwards

------------

Welding current On/Off TT 1 TT 1 TT 1 TT 1 Secondary current TT 2 TT 2 TT 2 TT 2


TT 1 TT 1 TT 1 TT 1

Increase / reduce welding

current ------------------- ------------------- Turn

potentiometer

backwards / forwards

------------

* Stop mode: Machine switched on and ready for operation; before and after welding.

3.9.2.4 Modes 1-4 for up/down torch with LED display (12-pole connection socket)

Machine version with 12-pole torch trigger connection socket for up/down torch with LED display required.

BRT1

Down

Up

BRT2

Up/down torch with LED display. The LED display will precisely reflect the display on the machine. Front right rocker (larger) for torch trigger TT1 (push rocker forwards) and TT2 (push rocker backwards). Back left rocker (smaller) for Up (push rocker forwards) and Down (push rocker backwards). See figure on the left

Symbol Functions Mode 1 Mode 2 Mode 3 Mode 4

Welding current On / Off TT1 TT1 TT1 TT1

Secondary current BRT2 BRT2 BRT2 BRT2 Secondary current in

tapping mode TT1 TT1 TT1 TT1


Up/Down ------------------- ------------ -----------

JOB mode selection only possible in Stop mode*

------------------- ------------------- ------------ Tap TT2

Select JOBs up/down ------------------- Up/Down ------------ Up/Down Gas test (gas flows 30s)

only possible in Stop mode*

------------------- ------------------- ------------ Press TT2 for 3 secs.

Increase / reduce

welding current 1st jump = adjustable (see 3.9.2.6)

------------------- ------------------- ------------ Up/Down

3.9.2.5 Modes 11-14 without tapping mode

Modes 11-14 are the same as modes 1-4 but without tapping mode. The following applies:

• Mode 1 corresponds to mode 11





3/23

3.9.2.6 Setting the first jump when increasing or reducing the welding current

This function is only possible with up/down torches in modes 4 and 14.


1 x

Press key buttons (H1) and (D1) simultaneously.

AMPAMPJOB

Set a welding current of 1-10A

1 x

Save the setting. Press key button (H1) or wait 2 secs.

Increase first jump for welding current Reduce first jump for welding current

AMP

B

t Fig. 3/9

AMPB

t Fig. 3/10

B = 1 - 10A


3/24

3.9.3 Percentage or absolute values for the ignition or end-crater current



AMPAMPJOB


Percentage or absolute

or

AMPAMPJOB

Set percentage (pro) or absolute (abs) Percentage setting: Ignition current (TIG), end-crater current (TIG) and hotstart current (MMA) can be set as a percentage of the main current. Absolute setting: Ignition current (TIG), end-crater current (TIG) and hotstart current (MMA) can be set using absolute values.

or

Select positive ignition pulse

Safe ignition with the positive ignition pulse for applications using helium gases and helium gas mixtures.

or

AMPAMPJOB

Setting positive ignition pulse Positive ignition pulse switched off

Positive ignition pulse switched on


3/25

3.9.4 Fan test, querying the manufacturer code and setting the mains current limit



AMPAMPJOB


Fan test

AMPAMPJOB

Initiate fan test (phone)

Manufacturer code

Mains current limit

or

AMPAMPJOB

Set mains current limit (16A or 10A)

or

3.9.5 Changing the three-digit code



AMPAMPJOB


First digit of the current code. Digit will flash.

AMPAMPJOB



3/26


Second digit of the current code. Digit will flash.

AMPAMPJOB


Third digit of the current code. Digit will flash.

AMPAMPJOB


3s

If the code is incorrect the display shown on the right will appear and the code will need to be re-entered.

3s

If the code is correct, the display shown on the right will appear briefly and the first digit of the new code can be entered. Digit will flash.

AMPAMPJOB


Second digit of the new code. Digit will flash.

AMPAMPJOB


Third digit of the new code. Digit will flash.

AMPAMPJOB


3s

3.9.6 Exiting the Basic Settings menu



AMPAMPJOB


It is only possible to exit the menu options using the procedure given above.


3/27

3.10 Resetting to the delivery condition

All customised information set and saved will be lost. In addition to the values set (see chap. 3.1) all further settings such as the torch modes, up/down speed, etc. will be reset to the condition on delivery. Control element Action Result Display

Simultaneously press the trigger buttons (G1) and (B1) when switching on the machine.

The following values are factory set:

Setting Works setting Setting options blocked or enabled

Enabled

Torch mode 1 Up/down speed 0,3s/0,1s Percentage or absolute values Percentage Mains current limit setting 16A Code setting 000 Positive ignition pulse Switched off (DC-)


3/28

3.11 JP1: Configure welding torch connection When connecting a potentiometer torch, jumper JP1 needs to be unplugged inside the welding machine (see fig. 2/6):

Welding torch configuration Setting

Prepared for TIG standard or up/down torch (factory setting) JP1

Prepared for potentiometer torches JP1

Observe the safety precautions given in the standard operating instructions.

Observe accident prevention regulations.

All conversion and retrofitting work must be performed by a qualified electrician in compliance with current VDE regulations.

Disconnect from the mains before opening. Switching off is not sufficient. Wait for 2 minutes until the capacitors have discharged.

It is absolutely essential that a VDE 0702, VBG 4 and VBG 15 repetition test is performed before re-commissioning the machine. For more detailed instructions, please see standard operating instructions for the welding machine.

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Fig. 3/11 T200/1 control

4 Quick start – the fastest way to weld

4/1

Preparations Setting Fault elimination

• Plug in the mains plug. (Remember fuse!)

• Set the welding process SS S safety sign LED:

If the LED is off, call the service dept.

+

• Plug in the workpiece lead, lock and attach conductively to the workpiece.

PulsAC/DC

Puls• Select TIG pulses TIG-AC/DC pulses

or standard TIG welding

Excess temperature LED is on:

• Duty cycle exceeded > allow machine to cool

- • Insert torch welding current plug

• Select the operating mode.

Water deficiency LED:

• During operation with a cooling module the water deficiency LED will be on.

• Connect torch trigger plug.

• Establish the shielding gas supply, adjust the gas flow

AMPAMPJOB

• Select all adjustable welding parameters for the TIG process using the key button and set the rotary transducer:

• Main current AMP, secondary current AMP%, gas pre-flow time, ignition current, up-slope time, pulse current time, pause current time, down-slope time, end-crater current, gas post-flow time, electrode diameter, balance, frequency.

Collective interference LED:

• Power unit is switched off. Some errors are short-term, one-off errors and the collective interference signal light will go off again and the welding machine will be ready for welding once more. If the signal light continues to be on, see chap. 7.

• Plug in the remote control connection plug

HF

HF • Set the ignition mode: HF ignition Liftarc (contact ignition)

• Switch on machine at the main switch

5 Commissioning

5/1

5.1 Area of application

5.1.1 Proper usage These welding machines are suitable exclusively for TIG and MMA welding. Any other use is regarded as "improper" and no liability is assumed for any damage arising therefrom.

We can only guarantee smooth and trouble-free operation of the machines when used in conjunction with the welding torches and accessories from our range.

• MMA directff current welding for rutile and basic coated electrodes.

• TIG DC and AC welding with HF ignition or Liftarc TIG-DC: Unalloyed, low-alloy and high-alloy steels, copper, nickel-based alloys and special metals. TIG AC/DC: Aluminium and aluminium alloys

5.2 Setting up the welding machine

Follow the safety instructions on the opening pages entitled "For your safety".

Set up the machine so that there is sufficient space to adjust the operating elements.

Ensure that the machine is set up in a stable position and is appropriately secured.

5.3 Mains connection

The operating voltage shown on the rating plate must match the mains voltage!

For mains fuse protection, please refer to the technical data (chapter 1).

• Insert mains plug into the appropriate socket when the machine is switched off.

5.4 Welding machine cooling system In order to achieve the optimum duty cycle for the power units, please observe the following conditions:

• Ensure that the working area is adequately ventilated,

• Do not obstruct the air inlets and outlets of the machine,

• No metal parts, dust or other foreign bodies are permitted to enter the machine.

5.5 Workpiece lead, general

Remove paint, rust and dirt from clamping and welding areas with a wire brush. The workpiece clamp must be mounted near the welding point and must be fixed in such a way that it cannot come loose of its own accord.

Structural parts, pipes, rails etc. may not be used as return leads for the welding current unless they are the workpiece themselves. A perfect current connection must be ensured for welding benches and appliances.

5 Commissioning

5/2

A1

B1

C1

D1

J1

I1

H1

G1

F1E1

Fig. 5 / 1 TRITON 180; 220 AC/DC connections

A1

B1

C1

D1

G1

F1

J1

H1

Fig. 5 / 1 TRITON 180 DC connections

5 Commissioning

5/3

5.6 MMA welding

If welding is carried out alternately using TIG and MMA welding and if a welding torch and an electrode holder are connected to the machine, the open-circuit/welding voltage is applied simultaneously to both.

The torch and the electrode holder should therefore always be placed on an insulated surface before starting work and during breaks.

When replacing spent or new stick electrodes, always switch off the machine at the main switch.

Always use insulated tongs to remove used stick electrodes or to move welded workpieces. Always put the electrode holder down on an insulated surface.

5.6.1 Electrode holder • Insert cable plug of the electrode holder into the welding current socket (C1 "+" or D1 "-") and

lock by turning to the right.

The polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.

Clamp stick electrode into electrode holder. Caution: Risk of injury from crushing! Always put down stick electrode holder on an insulated surface.

5.6.2 Workpiece lead • Insert cable plug of the workpiece lead into the welding current socket (C1 "+" or D1 "-") and

lock by turning to the right.

The polarity depends on the instructions from the electrode manufacturer given on the electrode packaging.

5.7 TIG welding

If welding is carried out alternately using TIG and MMA welding and if a welding torch and an electrode holder are connected to the machine, the open-circuit/welding voltage is applied simultaneously to both.

The torch and the electrode holder should therefore always be placed on an insulated surface before starting work and during breaks.

We can only guarantee the perfect functioning of our machines when used with our range of welding torches.

TIG welding torches with shielded torch trigger control leads should not be connected (see torch operation instructions).

Follow the safety instructions on the opening pages entitled "For your safety". Before welding with a cooling module ensure that all coolant hoses are connected.

5.7.1 Welding torch, general

Always put down welding torch on an insulated surface. Prepare welding torch according to the welding task in hand (see torch operating instructions).

• Fit tungsten electrode and gas nozzle onto the welding torch (observe current load, see torch operating instructions).

• Insert the welding current plug in socket "-" (D1) and lock by turning to the right.

• Insert the torch trigger plug in the socket (B1) and tighten.

• Screw shielding gas connection of the welding torch tightly on to the connection nipple G¼ (A1) (welding current potential "-").

• For water cooled torches: Engage the rapid-action closure nipple of the TIG torch in the rapid-action closure coupling for the coolant supply (blue) and return (red) lines of the cooling module.

5 Commissioning

5/4

5.7.2 Standard TIG welding torch

The welding machine must be fitted with the 5-pole connection socket (standard). If the welding machine is fitted with an 8-pole connection socket, an adapter (see Accessories) must be used.

• Insert the torch control lead plug (5-pole) into the connection socket (A1) and lock.

The welding machines are supplied as standard with torch trigger pin assignment B1 and gas connection G1/4".

5

4

3

2

1

BT

I1

I2

Fig. 5/5: Connection socket connection B1

5.7.3 TIG up/down and TIG potentiometer welding torch

The welding machine must be fitted with the optional 8-pole connection socket.

A

C

E

D

G

H

F

B

Poti UD/einPoti UD/ein

IH-Down

Uref 10VUref 10V

Up

0V

BT1

BT2

UpDown

+ -

BT2

+

BT1

-

Fig. 5/6 Connection socket assignments Up/down torch

Uref 10VUref 10V

IH-Down

Poti UD/einPoti UD/ein

Up

H

G

E

F

10k

0V C

D

BT1

BT2

A

B

Fig. 5/7: Connection socket assignments

Potentiometer torch

5.7.4 TIG up/down welding torch with LED display (TRITON 220 DC; TRITON 180, 220 AC/DC) Machine version with 12-pole torch trigger connection socket for up/down torch with LED display required.

The welding machine must be fitted with the 12-pole connection socket.

5 Commissioning

5/5

5.7.5 Shielding gas supply (shielding gas cylinder to the welding machine)

No impurities must be allowed to enter the shielding gas supply, as these would cause blockages in the shielding gas supply. Before connecting the pressure reducer to the gas cylinder, open the cylinder valve briefly to blow out any dirt. All shielding gas connections must be gastight.

• Place shielding gas cylinder in the retainer provided for it and secure with chains.

• Before connecting the pressure reducer to the gas cylinder, open the cylinder valve briefly to blow out any dirt present.

Connection: • Mount the pressure reducer on the gas cylinder valve.

• Screw the gas hose tightly to the pressure reducer and G ¼" connecting nipple on the rear of the welding machine (F1).

Adjustment: • Switch on machine at the main switch (G1).

• Select the TIG welding process with key button (chap. 3, C1). • Select latched mode using the key button (chap. 3, D1).

During the adjustment, the open-circuit voltage is applied to the torch electrode (after the torch trigger has been pressed).

• Press and release the torch trigger.

• Slowly open the gas cylinder valve.

• Set the required amount of shielding gas on the pressure reducer, about 4 – 15 l/min depending on the current strength and the material.

Rule of thumb for gas flow rate: Diameter of gas nozzle in mm corresponds to gas flow in l/min. Example: 7 mm gas nozzle corresponds to 7 l/min gas flow

5.7.6 Workpiece lead • Insert cable plug of the workpiece lead into the welding current socket (C1 "+") and lock by

turning to the right.

5.8 Cooling unit function specification (TRITON 220 DC; TRITON 180, 220 AC/DC) A functional test is performed on the cooling module after the welding machine has been switched on.

The coolant pump and the fan are switched on. When the pump is running, the coolant level is sufficient and there is enough throughput, the cooling module is shut down.

If the throughput is not sufficient a coolant error is reported and the pump runs for a maximum of 2 minutes so that the operator can top up the coolant.

The cooling module is switched on at the start of the TIG welding process. After the welding process has stopped, the water pump and fan continue to run for a further 5min and then switch off.

5.8.1 Coolant error If there is no throughput for more than 2.5 secs. during the welding operation, e.g. because of a lack of coolant, pump failure or a burst or leaking hose:

• an error message is issued (chap. 3, W1: Water deficiency LED)

• and the welding process is ended in a controlled manner (coolant pump and power unit of the welding machine are switched off).

When the welding process is re-started, the coolant error is reset and the cooling module is switched on. If still no throughput has built up after 2.5 secs., the cooling module is switched off, the water deficiency LED (chap. 3, item W1) comes on and the welding process is ended in a controlled manner.

6 Maintenance and care

6/1

6.1 General Under the indicated environmental conditions and normal operating conditions, this machine is largely maintenance-free and requires minimum care. However, a number of points should be observed to guarantee fault-free operation of your welding machine. Among these are regular cleaning and checking as described below, depending on the level of contamination in the environment and the usage time of the welding machine.

Cleaning, testing and repairing of the welding machines may only be carried out by competent, capable personnel. A capable person is one who, due to training, knowledge and experience, is able to recognise the dangers that can occur during testing of welding power sources as well as possible subsequent damage and who is able to implement the required safety procedures.

In the event of failure to comply with any one of the following tests, the machine must not be operated again until it has been repaired and a new test has been carried out.

6.2 Cleaning

Before cleaning, carefully disconnect the machine from the mains. PULL OUT THE MAINS PLUG.(Switching off or pulling out the fuse does not provide adequate insulation protection) Wait 2 minutes until the capacitors are discharged. Remove the casing cover.

The individual components should be handled as follows:

Power source: Depending on the amount of dust, blow out power source using oil- and moisture-free compressed air.

Electronics: Do not blast electronic components or circuit boards with compressed air but instead use suction from a vacuum cleaner for cleaning purposes.

6.3 Repetition Test conforming to E VDE 0544-207, conforming to the German Ordinance on Operational Safety

In addition to the regulations on the repetition test mentioned here, the relevant laws and regulations in the country of use must be observed.

The repetition test must be conducted in accordance with E VDE 0544-207 “Repetition Test on Arc Welding Equipment”. The draft standard summarises all the necessary test points specifically for welding machines as already cited together in the VDE 0702 “Repetition Test for Electrical Devices”, with the addition of special application notes and different limit values.

Unfortunately, many test devices for VDE 0702 are not completely suitable due to the special conditions in inverter arc welding machines!

Recommendation: Ask your test engineer whether he is performing the test in accordance with E VDE 0544-207, the measuring equipment conforms to VDE0404-2 and the frequency response is being evaluated in accordance with DIN EN 61010-1 Appendix A – Measuring Circuit A1. Have this confirmed in writing if necessary.

EWM as a manufacturer has specified a separate test device and provides its EWM dealers with the necessary support to conduct a repetition test to E VDE 0544-207 correctly.

If the repetition test is not conducted in accordance with the standards and / or not at the prescribed intervals, the right to claim under the warranty lapses!

The following description of the repetition test is only a brief overview of the products to be tested. For details on the test points or in the event of any queries, please read E VDE 0544-207.


6/2

6.3.1 Test intervals and scope A quarterly partial test and an annual extensive test are to be carried out. The extensive test must also be carried out each time that repairs are made; in the case of heavy use, the period can be reduced (e.g. to 6 months when used at construction sites). In the extensive test, the machine must be opened and cleaned according to the section entitled “Cleaning”. Only exterior cleaning is required for the partial test.

Partial test Full test

a) Visual check a) Visual check b) Electrical test: measurement of Protective

conductor resistance b) Electrical test: measurement of

• Protective conductor resistance • Insulation resistance • Leakage currents • Open circuit voltage

c) Functional test c) Functional test

6.3.2 Documentation of the test The result of the test must be documented to show the following clearly:

• • Identify the tested machines,

• • The date of the test

• • The time of the next test and

• • The results

for later reference. The machine must be marked if the test is successful (e.g. with a test plate). This plate must include the date of the next repetition test.

6.3.3 Visual inspection Given below are the main points in the full test. The points to be tested with the machine open are not required for the partial test.

• 1. Torch/stick electrode holder, welding current return lead clamp

• 2. Leads including plugs and couplings

• 3. Open plugs and couplings

• 4. Casing

• 5. Open casing

• 6. Special features of the welding power sources for plasma cutting

• 7. Operating, message, safety and adjustment devices

• 8. Other, general condition

6.3.4 Measurement of protective conductor resistance Measure between the plug earthed contact and accessible metal parts, e.g. casing screws. During the measurement, the connection lead must be moved across the entire length, but especially close to the casing and plug inputs. This should uncover any interruptions in the protective conductor. All conductive parts of the casing accessible from outside should also be tested to ensure a correct PE connection for safety class I.

The resistance must not exceed a mains connection lead 0.3 Ω up to 5m in length. For longer leads, the permissible value increases by 0.1 Ω per 7.5m of lead.


6/3

6.3.5 Measurement of insulation resistance The mains switch must be on before the insulation in the interior of the machine through to the transformer can be checked. If a mains contactor is fitted, this should be bridged or the measurement must be carried out on both sides.

The insulation resistance must not be less than:

Input power circuit (mains)

against Welding current circuit and electronics

5 MΩ at test voltage 1000V=

Input power circuit (mains)

against Casing (PE) 2.5 MΩ at test voltage 500V =

Welding current circuit and electronics

against Casing (PE) 2.5 MΩ at test voltage 500V =

6.3.6 Measuring the leakage current (protective conductor and contact current) These measurements cannot be carried out with a normal multimeter. Even test devices for VDE 0702 (especially older devices) are generally only intended for 50/60Hz. With inverter welding machines, however, significantly higher frequencies occur, which can interfere with some measuring devices, and results in others measuring the frequency incorrectly.

Test devices must meet the requirements of VDE 0404-2. For the frequency response measurement, please refer to DIN EN 61010-1 Appendix A – Measuring Circuit A1.

For these measurements the welding machine must be switched on and supplying open circuit voltage.

• 1. Protective conductor current: <3.5mA

• 2. Contact current from welding sockets separately to PE: <10mA

• 3. Contact current of accessible, conductive parts not connected to PE, to PE: <0.5mA

6.3.7 Measuring the open circuit voltage

6u8F10nF

0...5k

0k2

1k0 1N 4007

Measuring circuit to DIN EN 60974-1

Connect the measuring circuit to the welding current sockets. The voltmeter must display mean values and must have an internal resistance ≥ 1 MΩ. During the measurement, adjust the potentiometer from 0 kΩ to 5 kΩ. The voltage measured should not deviate from that given on the rating plate by more than +/- 5% and must not be greater than 113V (for machines with VRD: 35V).

6.3.8 Function test of the welding machine Safety devices, selector switches and command units (if fitted) and the entire machine or the entire system for arc welding, must be functioning perfectly.

• 1. Main switch

• 2. Emergency stop devices

• 3. Danger reduction devices

• 4. Gas solenoid valve

• 5. Message and control lamps

• 6. Command devices and selector switches (including remote controls)

• 7. Locks


6/4

6.4 Repair Work Repair and maintenance work may only be performed by qualified and authorised specialist staff; otherwise the right to claim under warranty is void. In all service matters, always consult the dealer who supplied the machine. Return deliveries of defective equipment subject to warranty may only be made through your dealer. When replacing parts, use only original spare parts. When ordering spare parts, please quote the machine type, serial number and item number of the machine, as well as the type designation and item number of the spare part.

We hereby confirm that the servicing and maintenance guidelines given above, and the repetition test described above, have been conducted correctly in accordance with E VDE 0544 207.

Date / Stamp / Signature of EWM sales partner Date / Stamp / Signature of EWM sales partner

Date of next repetition test Date of next repetition test





7 3-Year Warranty

7/1

7.1 General Validity 3 year warranty

on all new EWM machines:

• Power sources • Wire feeds • Cooling units • Trolley

1 year warranty

on remote controls and used EWM machines.

6 month warranty

on spare parts supplied separately (e.g. circuit boards, ignition units).

Replaceable parts are components that are subject to mechanical ageing (e.g. motors, gears, pumps, fans, WF rollers, wheels, solenoid valves, etc.) and are thus excluded from the warranty. This information applies regardless of statutory warranty rights and is based on our General Terms and Conditions as well as our accompanying Warranty Regulations.

7 3-Year Warranty

7/2

7.2 Warranty Declaration Your 3-year Warranty

Regardless of statutory warranty rights and based on our General Terms and Conditions, EWM HIGHTEC WELDING GmbH provides a 3-year warranty for its welding products starting on the date of purchase. Different warranty periods apply for accessories and spare parts; please see the “General Validity” section for these periods. Wearing parts are of course exempt from the warranty.

EWM guarantees the error-free condition of our products in terms of materials and processing. If the product proves to be defective in terms of materials or processing within the warranty period, you have the right to free repair or to replacement by an appropriate product, at our discretion. In this case, the returned product becomes the property of EWM when it reaches Mündersbach or our premises. Note

Only machines that are inspected and maintained regularly function correctly in the long term. For this reason, please ensure that all the points given in your operating instructions are followed, especially in the “Maintenance and Care” chapter. Making a Claim

When making a claim under the warranty, please contact only your EWM-authorised sales partner. Exclusion of Warranty

The warranty does not apply to products that are damaged due to accidents, misuse, improper operation, incorrect installation, use of force, disregard of the specifications and operating instructions, insufficient maintenance (see “Maintenance and Care” chapter), exterior influences, natural disasters or personal misfortunes. Furthermore, it is not valid in the case of improper changes, repairs or modifications. In addition, a claim against the warranty does not exist in the case of partially or completely dismantled products and interventions by persons who are not authorised by EWM, as well as in the case of normal wear. Limitation

All claims regarding fulfilment or non-fulfilment on the part of EWM from this declaration in connection with this product are limited as follows to the replacement of the actual damages. EWM’s liability originating from this declaration in connection with this product is strictly limited to the amount that the purchaser originally paid for the original purchase. This limitation does not apply to personal injuries or damage to property caused by negligent behaviour on the part of EWM. In no way will EWM be responsible for lost profits, indirect or subsequent damage. EWM is not liable for damages based on the claims of third parties. Place of Jurisdiction

If the person making the order is a business person, the sole place of jurisdiction for all disputes resulting directly or indirectly from the contractual relationship shall be the headquarters or the branch office of the supplier, at the discretion of the supplier. The purchaser gains ownership of the products supplied as replacements within the framework of the warranty adjustment at the time of the exchange.

8 Operating problems, causes and remedies

8/1

8.1 Error messages • In the event of a machine error, an error code (see table below) is shown on the display

(chap. 3, A1).

• If multiple errors occur, these should be rectified in sequence.

Error message Possible cause Remedy

"E1" Water error Only occurs when the water cooler is connected.

Ensure that sufficient water pressure can be built up. (e.g. top up water)

"E2" Temperature error Allow machine to cool down.

"E3" Electronics error Switch the machine off and back on again. If the error persists, inform the service dept.

"E4" See "E3" See "E3"

"E5" See "E3" See "E3"

"E6" Balancing error in voltage recording. Switch off the machine, place the torch in an insulated position and switch the machine back on. If the error persists, inform the service dept.

"E7" Balancing error in current recording. Switch off the machine, place the torch in an insulated position and switch the machine back on. If the error persists, inform the service dept.

"E8" Error in one of the electronics supply voltages or excess temperature of the welding transformer.

Allow machine to cool down. If the error message persists, switch the machine off and back on again.

If the error persists, inform the service dept.

"E9" Low voltage Switch off the machine and check the mains voltage

"E10" Secondary excess voltage Switch the machine off and back on again. If the error persists, inform the service dept.

"E11" Excess voltage Switch off the machine and check the mains voltage

9 Spare parts list

9/1

TRITON 180*, TRITON 220 DC, TRITON 220 AC/DC

A1

B1

C1

D1

E1

F1

G1

H1

I1

J1 Fig. 8/1: front view

Item Designation Description TRITON 220

A1 Griffstange Hand grip 094-007501-00003

B1 Halterung für Griffstange Hand grip mount 094-007383-00003

C1 Gehäusewinkel Casing angle 094-007900-00006

D1 Steuerung T200AC/DC komplett (TRITON 220 AC/DC)

Control T200AC/DC complete (TRITON 220 AC/DC)

040-000611-00000

o. Abb.

Steuerung T200DC komplett (TRITON 220 DC)

Control T200DC complete (TRITON 220 DC)

040-000612-00000

Drehknopf Rotary dial 074-000315-00000 E1

Drehknopfdeckel Rotary dial cap 074-000315-00001

Drehknopf 16mm (nur TRITON 220AC/DC)

Rotary dial 16mm (only TRITON 220 AC/DC)

094-000131-00000

Drehknopf Deckel 16mm (nur TRITON 220AC/DC)

Rotary dial cap 16mm (only TRITON 220 AC/DC)

094-000131-00001

F1

Drehknopf Pfeilscheibe 16mm (nur TRITON 220AC/DC)

Rotary dial arrow indicator 16mm (only TRITON 220 AC/DC)

094-000131-00002

G1 Anschlußbuchse Connection socket 074-000232-00000

H1 Anschlußbuchse 5-polig (Standard) Connection socket 5-pole (standard) 074-000233-00000

Anschlußnippel G1/4 Connection nipple 094-002695-00001

Isolierstück Insulation piece 094-000075-00000

Druckscheibe Pressure washer 094-000076-00000

Mutter M20 Nut M20 094-000068-00000

I1

Fächerscheibe Fan-type lock washer 094-006516-00000

J1 Gummifüße Rubber feet 094-001718-00001 Geräteausführung für Up/Down-Brenner mit LED-Anzeige:

H1 Anschlußbuchse 12-polig komplett Connection socket 12-pole complete 094-008106-00000

*TRITON 180 in preparation

9 Spare parts list

9/2

A2

B2

C2

D2

E2

F2

G2

H2

Fig. 8/2 rear view

Item Designation Description TRITON 220

A2 Kippschalter Toggle switch 094-001898-00000

B2 Anschlußbuchse 8-polig Connection socket, 8-pole 094-006904-00000

C2 Anschlußbuchse 19-polig Connection socket, 19-pole 094-003064-00000

D2 Netzschalter Mains switch 094-008045-10000

Anbau Gehäuse Extension housing 094-006861-00000

Abdeckkappe Cap 094-006862-00000

E2

Buchseneinsatz Socket insert 094-007943-00000

Kabeldurchführung Screwed cable gland 094-007871-00000 F2

Gegenmutter Counter nut 094-007878-00000

G2 Magnetventil G1/4 Solenoid valve 094-005497-00001

H2 Netzkabel Mains cable 094-005142-00001

9 Spare parts list

9/3

A3G3

F3

B3

C3

D3

E3

Fig. 8/3: left side (TRITON 220 DC)

Item Designation Description TRITON 220 DC

A3 Drossel-Hochsetzsteller Choke power factor correction 044-002685-00000

B3 Haupttrafo Main transformer 092-001560-00001

C3 Lüfter Fan 094-007861-00000

D3 Sekundärdioden Secondary diode 044-002312-00000

E3 LEM-Wandler LF205-S/SP1 LEM-converter LF205 S/SP1 044-002691-00000

F3 PCB Spannungsverdoppler SV2/1 PCB voltage doubler SV2/1 040-000533-00000

G3 PCB Brennertasterfilter BTF1 PCB torch trigger filter BTF1 040-000545-00000

9 Spare parts list

9/4

A4

H4

G4F4

B4

C4D4

E4

Fig. 8/4: right side (TRITON 220 DC)

Item Designation Description TRITON 220 DC

A4 Steuerung T200/1 Control T200/1 040-000609-00000

B4 Steuerung T201/2 DC Control T201/2 DC 042-000653-00000

C4 PCB Zündgerät HFAC4 PCB ignition unit HFAC4 040-000622-00000

D4 Steuerung DC 220 Control DC 220 040-000587-00000

E4 HF-Drossel HF choke 072-000536-00000

F4 Frontblech Front panel 094-008003-00005

G4 Bodenblech Floor panel 094-007705-00003

H4 Rückblech Rear panel 094-007706-00003

9 Spare parts list

9/5

A5H5

G5

F5

B5

C5D5

E5

Fig. 8/5: left side (TRITON 220 AC/DC)

Item Designation Description TRITON 220 AC/DC

A5 Drossel-Hochsetzsteller Choke power factor correction 044-002685-00000

B5 Haupttrafo Main transformer 092-001560-00001

C5 Lüfter Fan 094-007861-00000

D5 Sekundärdioden (4x) BYT200 PIV400

Secondary diodes (4x) BYT200 PIV400

044-002601-00000

E5 Wechselrichter-Module (4x) GA200SA60S

Inverse rectifier moduls (4x) GA200SA60S

074-000600-00000

F5 LEM-Wandler LF205-S/SP1 LEM-converter LF205 S/SP1 044-002691-00000

G5 Wechselrichtertreiberstufe TRF5 Inverse rectifier drive stage TRF5 040-000618-00000

H5 PCB Brennertasterfilter BTF1 PCB torch trigger filter BTF1 040-000545-00000

9 Spare parts list

9/6

A6

G6

I6

J6

L6

K6

H6

F6

B6

C6

D6

E6

Fig. 8/6: right side (TRITON 220 AC/DC)

Item Designation Description TRITON 220 AC/DC

A6 PCB Schweißelektronik T200/1 PCB welding electronics 040-000609-00000

B6 PCB Tastatur T200/2 AC/DC PCB key board T200/2 AC/DC 042-000652-00000

C6 PCB Zündgerät HF AC4 PCB ignition unit HF AC4 040-000622-00000

D6 Frontblech Front panel 094-008002-00005

E6 HF Drossel HF choke 072-000536-00000

F6 Gehäuse Bodenblech Floor panel casing 094-007705-00003

G6 PCB Power Sinus DC 220 PCB Power Sinus DC 220 040-000587-00000

H6 Rückblech Rear panel 094-007706-00003 Zusätzlich für Geräteausführung mit Up/Down-Brenner (LED-Anzeige):

I6 Sättigungswandler Saturation transformer 044-000967-00000

J6 PCB Weiche WTC1 PCB WTC1 040-000625-00000

K6 Schutzbeschaltung IGRO/1 PCB protective wiring IGRO/1 040-000629-00000

L6 PCB Brennertasterfilter BTF1 PCB torch trigger filter BTF1 040-000545-00000

10 Accessories, options

10/1

10.1 TRITON 220 DC and TRITON 220 AC/DC

10.1.1 Standard TIG torch Designation, description Item No.

TIG torch 26 GD, 4m, two triggers 094-000538-00000TIG torch 20 WD, 4m, two triggers 094-000487-00000

10.1.2 TIG up/down torch Designation, description Item No.

Opt. 8-pole connection socket for potentiometer and up/down torch 092-001530-00000TIG torch 26 up-down GD, 4m 094-007549-00000TIG torch 20 up-down WD, 4m 094-007535-00000

10.1.3 TIG current control torch Designation, description Item No. Current control TIG torch U/DLED W 3m 094-008112-00000

10.1.4 Electrode holder /workpiece lead Designation, description Item No. Electrode holder, 35mm2, 4m 092-000052-00000 Workpiece lead, 35mm2, 4m, pole binder 092-000008-00000

10.1.5 Remote control / connection cable Designation, description Item No. RTF1 foot-operated remote control current On/Off 5m, 19-pole 094-006680-00000 RT1 H remote control current without cable 090-008097-00000 RT1 H remote control spot/pulse without cable 090-008098-00000 RTP2 H remote control spot/pulse without cable 090-008099-00000 RA5M19 connection cable 5m 19-pole 092-001470-00005 RA10M19 connection cable 10m 19-pole 092-001470-00010 RA20M19 connection cable 20m 19-pole 092-001470-00020

10.1.6 General accessories Designation, description Item No. COOL20 U20 air-cooling unit 090-008104-00102 TROLLY 31-2 construction site transport vehicle 090-008160-00000 Earthed coupling adapter to CEE16A plug 092-000812-00000 8-pole to 5-pole adapter for standard TIG torch 092-000940-00000 Adapter for central connection TIG torch to decentral connection TIG machines 094-008284-00000 DM2 pressure reducer flowmeter 16l/min 094-001980-00000 ADAP1 G1/4 to G1/8 threaded adapter 094-001650-00000

KF 23E-10 coolant 9.3l (frost protection -10 °) 094-000530-00000

KF 23E-200 coolant 200l (frost protection -10 °) 094-000530-00001

KF 37E-10 coolant 9.3l (frost protection -20 °) 094-006256-00000

10 Accessories, options

10/2

10.2 TRITON 180

10.2.1 Standard TIG torch Designation, description Item No.

TIG torch 26 GD, 4m, two triggers 094-000538-00000

10.2.2 TIG up/down torch Designation, description Item No.

Opt. 8-pole connection socket for potentiometer and up/down torch 092-001530-00000TIG torch 26 up-down GD, 4m 094-007549-00000

10.2.3 Electrode holder /workpiece lead Designation, description Item No. Electrode holder, 35mm2, 4m 092-000052-00000 Workpiece lead, 35mm2, 4m, pole binder 092-000008-00000

10.2.4 Remote control / connection cable Designation, description Item No. RTF1 foot-operated remote control current On/Off 5m, 19-pole 094-006680-00000 RT1 H remote control current without cable 090-008097-00000 RT1 H remote control spot/pulse without cable 090-008098-00000 RTP2 H remote control spot/pulse without cable 090-008099-00000 RA5M19 connection cable 5m 19-pole 092-001470-00005 RA10M19 connection cable 10m 19-pole 092-001470-00010 RA20M19 connection cable 20m 19-pole 092-001470-00020

10.2.5 General accessories Designation, description Item No. Earthed coupling adapter to CEE16A plug 092-000812-00000 8-pole to 5-pole adapter for standard TIG torch 092-000940-00000 Adapter for central connection TIG torch to decentral connection TIG machines 094-008284-00000 DM2 pressure reducer flowmeter 16l/min 094-001980-00000 ADAP1 G1/4 to G1/8 threaded adapter 094-001650-00000

11 Circuit diagrams

11/1

11.1 TRITON 180

11 Circuit diagrams

11/2

11 Circuit diagrams

11/3

11.2 TRITON 180 AC/DC

11 Circuit diagrams

11/4

11 Circuit diagrams

11/5

11.3 TRITON 220 DC

11 Circuit diagrams

11/6

11 Circuit diagrams

11/7

11.4 TRITON 220 AC/DC

11 Circuit diagrams

11/8

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